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Disclosed is
a method of obtaining improved cooling over
conventional plate fin laminates (Fig. 1).
The manufacturing process
involves (1) stamping plate-fins from conventional multigage strip,
(2) milling or skiving flow channels in the fins (Fig. 2) and finally
bonding them back-to-back to form the continous structure in Fig. 1.

In this
invention, folded plate fins (Fig. 2, dotted contour)
are used instead of straight fins, with similar manufacturing process
as the straight fin heat sink, with the exception of an additional
step of folding the fin prior to bonding.

In one
embodiment of this invention (Folded Plate-Fin Laminate)
as shown in Fig. 3, the fins are laminated with a flat spacer sheet
between adjacent fins. The depth of the
folds is equal to the height
of the step in thickness of the multigage stock material; the depth
and pitch of the folds will be approximately equal. Using the
nomenclature in Fig. 3, the area ratio of the folded fin flow channel
(Af) to parallel plate flow channel (A0) is Af/A0 = 1 - ((c-r)/p).
Consequently, in a 1 mm wide channel, the advantage of folds on a 1
mm pitch and rib thickness (r) = 0.25 mm
is a 75 percent increase in
surface area. Since the folds join the
adjacent fins in intimate
thermal contact, heat spreading does not solely take place in the
base but also in the fins over the entire fin height. Finally, fin
to fin joints increase the overall structural rigidity substantially.

In another
embodiment, the Alternate Folded Plate-Fin Laminate
(Fig. 4), a pair of folded fi...